Oh NO! What have I done! My new KZ1300

now that's the kind of thing I'd like to see waiting at my front door. Have fun putting them shinies in!

This next post starts with one part, a rubber boot between the swing arm and transmission that covers the drive shaft u-joint. It is clearly torn and needed to be replaced.



This part is impossible to find, I had been searching most of the summer for one. I ended up buying a complete rear end for the bike, swing arm, drive shaft, final drive, pivot bearings, etc. to get a boot in good shape. The parts were cheap the whole lot set me back about $75 with shipping. I thought I could resell some extra parts.... turns out I need them all. When I finally got the swing arm off I found the prop shaft tunnel had filled with water. The drive shaft U joint is toast, the tapered bearing for the swing arm pivot was frozen and the swing arm had rusted so badly the bearing race had broken loose. The whole swing arm is pretty much junk.







Some things must happen for a reason because now I have all of the parts to fix this mess.

I checked out the final drive, afraid it too had filled with water, it was ok. I checked the gear lash and it needs to be re-shimmed. The axle seals are leaking a bit. They are available so I order new seals. According to the shop manual I just need to remove the thinnest shim (0.1MM) and it should be back in sec when it goes back together.

Cleaned up the final drive, new seals and a shim adjustment. Ended up having to buy a .15mm shim to make it work out, I think I found the last one on the internet... All ready to roll now.




My cylinders came back from Fargo! I installed the new oil seal for the water pump drive, installed the mechanical water seal parts and painted it. I guess this is a 1370 now... :evil:







Getting excited now, my goal was to have the engine together before it gets too cold to work in the garage. I might pull it off but the snow is flying already.

congrats on the progress sir .

leon

Got the swing arm and final drive all back together. I picked up some Progressive air shocks form e-bay on the cheap. I replaced the seals in them and put the correct bushings in. Still need to polish them up a bit.

I still have to go through the breaks and replace the fork seals. But my list keeps getting shorter.

The replacement rubber boot...



Back together again

Tyler wrote: Got my head back from Larry..... Damn...

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Exhaust Port

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Intake Valves are soooo far back

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Other Side, man these must have been hard to work in

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The head looks fantastic, with a well done mild port job and new valves should run better than new. Great Job Larry, well done man!

Thanks Tyler... I hadn't been back to your project to see what's going on until tonight.

Those 1300 ports are long mothers. They have the same directional bias as 650 ports but with a whole lot more runner length. The factory was trying to shoot the charge into the cylinder on an angle to swirl it.

I see those new pistons have arrived... NICE!

Larry, can you shed some light on why the piston dom is offset? it wasn't done for clearance, for flow or flame front propagation maybe? it is clearly offset forward about .100 from centerline.

WOW !

I have always loved these bikes. I will be watching this progress. Nice work.

Thanks tk11b40

Big progress today....

I set the ring gaps and washed the new pistons and put on the new rings. Installed on the rods.






It took 3 people to get the cylinder block down, makes the 4 cylinder bikes look easy. This is a big step forward, the weather should warm up by the end of the week and I can get my head back on and torqued down. Then it will get put away until spring.

I did manage to get the head on before the really cold weather set in. This was my goal for the winter and leaves me in good shape to get her running this spring.

For now I am not sure if I want to re-grind the cams... it might be troublesome to get it tuned with so many things changing. I may leave the cams alone and get it dialed in then look at sending the cams off or finding another set to have reground.

Things left to do:
1. Finish the engine assembly Cams, Shim the valves, Thermostat, Radiator, Exhaust ( 6 into 1)
2. Install new coils under the seat, re-wire ignition.
3. Install a jet kit in the carbs (6 sigma stage 3)
4. Replace break lines, rebuild master cylinders, replace pads
5. Install new fork seals
6. Replace rear tire

Some of this I can work on during the winter, the rest will be waiting for me in the spring.

I hope Santa was good to everyone, Happy new year!!!

Engine is looking sweet. Nice work